hehe, my fan is/was cracked too, i forget which one was cracked, the original or the one i put in. nothing that some crazy glue can't fix
I do get the noise even when the climate controls are off.
padgett - I don't think that would be the problem at all, but it'd be interesting to check out. The noise does come sometimes as soon as you turn the HVAC stuff on. My guess is still a door/flap the directs the air. It sounds sorta like when you jiggle around the gas pedal around at 0% throttle, if you know what I mean. I thought it was that, initially, like a thottle cable on the fritz or something